A method of fabricating semiconductor devices

Abstract

 In wafer processes, after at least one layer which constitutes a structural member of a functional semiconductor element is formed on a semiconductor wafer, an excessive deposition brittle on an edge of the semiconductor wafer is removed by grinding or etching of the wafer edge until the underlying wafer is exposed. The removal of the deposition on the wafer edge reduces dust generation caused from crack and peel-off of the excessive deposition on the wafer edge, even if the wafer edge contacts a jig, etc.. Thus the reduction in dust generation improves production yields of highly integrated semiconductor devices.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

[0001] The present invention relates to a fabrication method of a semiconductor device, and particularly to a method to reduce dust generation out of its semiconductor wafer itself under the wafer processes.

Description of the Related Art

[0002] In recent years, as a result of advances of high density as well as high degree integration of semiconductor integrated circuits (referred to hereinafter as IC), semiconductor elements or wiring patterns having the minimum size below 1 µm has been achieved. Thus high integration capability has been accomplishing more than one million semiconductor elements on a single chip. Most of thus highly integrated semiconductor chip has an area of more than 70 mm². Thus finely fabricated elements of the structural members as well as thus increased area size of the IC chips have been causing a problem in that the quantity of the defects resulted from fine dust of 0.1 µm order during the wafer process affects yield of the IC fabrication.

[0003] It is known that the size of defects which affect the fabrication yield of the semiconductor devices is about one fifth through one tenth of the minimum width of wiring pattern of the semiconductor device. For example, for an IC whose design is based on 1 µm wiring width, defects of about 0.1 ∼ 0.2 µm in size caused from fine dust must be controlled. In an IC of about 20 mm² chip area, density of the above-described defects must be below 0.02 pieces/ mm² in order to achieve satisfactory yield. When the chip area is as large as about 70 mm², it is estimated that the defects density must be below 0.004 piece/ mm² in order to achieve the same yield.

[0004] There are two major sources of generating particles, such as dust, sticking onto a semiconductor wafer during wafer processes. One of them is fine dust included in the water, air or chemicals which may directly contact the semiconductor wafer. This dust is prevented by enhancing the cleanliness of the water, air or chemicals. Another source is, as shown in FIG. 1, small particles 50 and 60 generated when a piece 40 is cracked or peeled off from edge of the wafer 10. In FIG. 1, the wafer edge before generating the crack and peel-off is shown on the left hand side as well as the state after the crack and peel-off is shown on the right hand side. These cracks and peel-offs are generated during the wafer process by contacts of the semiconductor wafer with jigs, such as wafer holders or tweezers, to hold the wafer. Mechanisms of generating cracks is described later in detail. In order to prevent the crack and peel-off, in the prior art it has been a general measure that the shape and material of a portion in direct contact with the semiconductor wafer, of the jigs are appropriately chosen so that the force per unit area imposed upon the handled wafer becomes as little as possible

[0005] On the other hand, peripheral edges of the semiconductor wafer under process which frequently contact the jigs etc. have been chamfered or rounded in advance prior to the wafer process. However, no additional method to prevent dust generation out of the wafer under process has been particularly considered during the wafer processes.

[0006] FIG. 2 is a graph showing distribution of defects on a wafer surface, observed after the last step of wafer processes according to the prior art method in fabrication of a metal oxide semiconductor (referred to hereinafter as MOS) integrated circuit. The graph is of defects larger than 0.2 um in size distributed along radial direction of a silicon monocrystalline wafer of six inch diameter having MOS ICs of 2 µm design rule formed thereupon. As seen from the graph, the defects density is approximately 2 x 10⁻²/mm² almost constantly through the region apart more than 15 mm from the wafer edge towards the inside. However, the more edge-side the greater becomes the defects density. The reason why the defects density is greater on the wafer edge is believed that various layers 20 (FIG. 1) deposited on the wafer edge 10′ are peeled off to fall when the wafer edge touches a jig holding the wafer during the wafer processes as shown in FIG. 1, or dust generated from scratches on the wafer 10 itself floats up and deposits onto the wafer.

[0007] According to the facts described above, size of the defects which affect the production yield of a semiconductor device is found to be larger than about 1/5 ∼ 1/10 of the minimum wiring width of the semiconductor device. Therefore, when the size of the smallest portion of the semiconductor device to be fabricated is the order of several micron metres, dust size affecting the production yield can be relatively large, for example, larger than about 0.5 µm. Accordingly, even if dust is generated from the wafer edge as shown in FIG. 1, the quantity of the relatively large dust affecting the production yield is not so large, and such large dust will deposit on the wafer edge area which is close to the generation source; therefore, the effect rarely extends to the inner area of the wafer. However, if the semiconductor device should have fine elements, such as minimum wiring width below 1 µm, fine dust of as small as 0.1 µm order affects the production yield. Then, it is natural that the quantity of such fine dust becomes large. Furthermore, the fine dust of 0.1 µm order easily suspends in water or solution as well as floats in a gas stream. Accordingly, once the dust is generated, its effect not only stays in the vicinity of the generation source but also extends into the central area of the wafer, resulting in further reduction of the production yield of the semiconductor device.

[0008] The higher density, higher degree of, integrated IC requires the more complex structure. Accordingly, wafer processes for as many as more than 10 layers are then needed. During such processes, a semiconductor layer such as polycrystalline silicon layer, an insulating layer such as silicon dioxide or silicon nitride, or a metal layer such as aluminum wiring are deposited also on the wafer edge and grow as the wafer process is progressed. Prior to these processes for fabricating semiconductor elements, such as transistors, etc., the wafer has been prepared so that the wafer edge 1′ is chamfered or rounded as seen in the cross-sectional view in FIGs. 1 or FIGs. 3. This preparative treatment of the wafer is also disclosed in U.S. Patent No. 4,567,646 by Ishikawa et al., where a wafer edge on which silicon has been excessively grown during a silicon deposition process onto the wafer is trimmed to be round. Even though the wafer has been thus prepared, on the wafer edge an abnormal layer growth, such as a thicker layer than that formed on the flat primary plane of the wafer, is likely to further take place in each process step for fabricating thereon semiconductor elements, such as transistor and its wiring etc., because there is exposed a crystalline plane distinct from the primary plane of the wafer. As the number of the layer formations is increased, the abnormal layer growths are accumulated to form a shape different from that of the underlying wafer edge, resulting in a protrusion on the edge. Such an protrusion on the edge easily generates a local stress by contacting a jig, accordingly, is likely to crack and peel off. Furthermore, different thermal expansion coefficients of each layer materials repeatedly cause thermal stresses on the laminated layers at each heat process. Therefore, the more number of the layer laminations make the protrusion the more it is likely to crack and peel off by the contact with the jigs etc.. An increase in the IC chip size has brought an increase in the semiconductor wafer size, accordingly, an increase in the weight. Therefore, thus increased wafer weight further increases a local stress imposed on the protrusion during the wafer handling. Thus, the peel off of the laminated layers on the wafer edge becomes more likely to take place. Because of these reasons, in conventional method dust generation out of the wafer itself during the wafer process can not be fully suppressed. This is one of major causes which prevent an achievement of a denser, accordingly, higher degree of, integration of ICs.

SUMMARY OF THE INVENTION

[0009] It is an object of the invention to provide a technique to reduce dust generation during wafer processes of high density, highly integrated semiconductor devices.

[0010] It is another object of the invention to improve production yield of high density, highly integrated semiconductor devices.

[0011] It is further object of the invention to allow an achievement of higher density, higher degree of, integrated semiconductor devices.

[0012] In wafer process according to the present invention, after at least one layer which constitutes a structural member of a functional semiconductor element is formed on a semiconductor wafer, an excessive deposition being brittle on an edge of the semiconductor wafer is removed by grinding or etching of the wafer edge until the underlying wafer is exposed. The removal of the deposition on the wafer edge reduces dust generation caused from crack and peel-off of the deposited layer on the wafer edge, even if the wafer edge contacts a jig, etc.. Thus the reduction in dust generation improves production yields of highly integrated semiconductor devices.

[0013] The above-mentioned features and advantages of the present invention, together with other objects and advantages, which will become apparent, will be more fully described hereinafter, with reference being made to the accompanying drawings which form a part hereof, wherein like numerals refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] 

FIGs. 1 show mechanism of generating dust caused from peel-off of a wafer edge.

FIG. 2 is a graph showing distribution of defects density on a processed wafer according to the present invention.

FIGs. 3 schematically illustrate steps of a preferred embodiment of the method of the present invention.

FIG. 4 is a graph showing defects density versus ground width from an edge of the wafer.

FIG. 5 is a graph showing a comparison of distribution of defects density along radial direction of the wafer, between the present invention and prior art.

FIG. 6 is a graph showing defects density versus position of a single grinding step during wafer processes.

FIG. 7 schematically illustrate the steps of a second preferred embodiment of the method of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Preferred embodiment of the present invention are hereinafter described in detail, in reference to the fabrication of a silicon MOS-type field effect transistor (referred to hereinafter as MOSFET) having 2 µm gate width and aluminum wiring. FIG. 3 schematically illustrates fabrication steps of a preferred embodiment of the present invention. In the figure, the numeral 1 denotes a silicon wafer; the numeral 2 denotes multiple layers formed on the semiconductor wafer; and the numeral 4 denotes a film formed after the grinding step. The semiconductor wafer 1 is a 6-inch diameter p-type silicon monocrystalline wafer with a (100) orientation. On the semiconductor wafer 1, a silicon dioxide film is formed so as to become later an element isolation 2-1 according to a known LOCOS (local oxidization of silicon) method. This isolation layer 2-1 according to the LOCOS extends thickly to the wafer edge 1′. Next, a silicon dioxide film to become a gate insulation film 2-2, and a polycrystalline silicon film to become a gate electrode 2-3 are sequentially deposited in lamination upon a region where an IC element, such as transistor, diode or resistor, is to be formed, according to a generally known method. At this time, this polycrystalline silicon film 2-3 is deposited also on the back of the wafer. Next, this laminated layers of the silicon dioxide film and the polycrystalline silicon film are patterned according to known photo lithography and etching techniques so as to form a 2 µm wide gate structure. Next, arsenic (As) is doped by a well-known ion-implantation method through windows opened by the previous patterning process, as an n-type impurity into the wafer 1. Next, the impurity is activated as well-known by heat anneal so as to form source and drain regions 3 of a MOSFET. Next, phospho-silicate glass (referred to hereinafter as PSG) film 2-5 as an inter-layer isolation film is deposited over the entire surfaces of thus processed wafer. Basically, these steps are not particularly different from fabrication steps of general MOSFETs. The silicon dioxide layers 2-1 and 2-2, polycrystalline silicon layer 2-3 and PSG layer 2-5 are referred to as the multiple layers 2. During these deposition steps of the multiple layer 2 the deposition of the multiple layer 2 produces on the wafer edge 1′ an abnormal protrusion as described in the Description of the Related Arts. This state is schematically illustrated in FIG. 3(a).

[0016] Next, a 2 µm thick positive photoresist film is coated as a protection layer (not shown in the figure) upon the PSG film surface where the IC elements are to be formed, according to a generally known spin coat method. This protection layer is in order to prevent a damage, a corrosion or a sticking material on thus processed wafer surface during the steps subsequent to grinding or etching of the wafer edge 1′. It is preferable that this protection layer can be selectively removed after completion of the grinding or etching step. Other plastic film, metal film or insulating film may be employed alternatively in place of the positive photoresist film. The multiple layers 2, i.e. silicon dioxide layers 2-1 and 2-2, polycrystalline silicon layer 2-3 and PSG layer 2-5, deposited on the wafer edge 1′ are removed by the use of a grinding wheel so as to expose the entire periphery 1′ of the underlying silicon wafer 1. This state is schematically illustrated in FIG. 3(b). A method and a device to grind the wafer edge by an employment of a grinding wheel is disclosed in Japanese Unexamined Patent Publication Tokukai Sho 62-154614. Ground width of the wafer measured from the original wafer periphery, denoted with GW between FIG. 3(a) and 3(b), is in a range of 0.5 ∼ 20 mm. The wafer edge grinding must be such that the abnormally grown protrusion 2′ of the deposited layers does not remain thereon, and is shaped round and mirror-finished, according to a chamfering process for general semiconductor wafers.

[0017] For accomplishing the mirror finish of the wafer edge, an additional etching step with an etchant of a mixture of hydrofluoric acid and nitric acid after the grinding step using a grinding wheel is effective. The photoresist used as a protective film for the grinding step being resistive also to this hydrofluoric acid/nitric acid etchant also functions as a mask for the etching step. Therefore, no corrosion takes place on the PSG film 2-5 or the silicon wafer 1 other than the exposed portion on the edge. After the grinding step, abrasive powder sticking to the wafer or particles of the ground-off wafer etc. are completely washed away with deionized water. Next, the now unnecessary photo resist is removed by a generally known ashing process in an oxygen plasma. For this photoresist removal step, the photo resist film may be removed by a wet process employing a generally employed resist stripping solution.

[0018] Next, contact holes reaching source and drain regions are respectively formed through the PSG film by a generally known photo lithography/etching method. An aluminum alloy layer, for example, containing 2% Si, to become an electrode and a wiring is deposited thereon by a generally known sputtering method. Finally, a passivation layer 4, typically composed of PSG film 4-1 and silicon nitride (SiN₄) film 4-2, is deposited thereover for passivating the IC elements. Thus, the wafer process is finished. This state is shown in FIG. 3(c).

[0019] Defects over 0.2 um in size on a wafer processed according to the above-described method are counted by the use of a particle counter. FIG. 4 is a graph showing relation of ground width of the wafer edge versus density of the above-described defects at the central area of the wafer. When the wafer edge was not ground at all (i.e. corresponding to the prior art) the defective density was approximately 2 x 10⁻² /mm² at the central area. However, an additional step of grinding the wafer edge as little as approximately 0.5 mm from the edge according to the present invention, between the steps of wafer process, has reduced the defect density at the central area down to approximately 1/2 of that of the prior art. Grinding of 10 mm from the edge has reduced the defects density down to approximately 5 x 10¹³/mm², i.e. approximately 1/4 of that of the prior art having no grinding step. An increase in the grinding width to 15 mm or 20 mm did not exhibit any remarkable change in the defect density at the central portion.

[0020] In a graph in FIG. 5, distribution of the defect density along wafer's radial direction is plotted with a solid line for a wafer having 5 mm ground width in comparison with that of the prior art wafer, having no grinding step, plotted with a dotted line. As seen from the graph, the wafer processed according to the present invention yields a sufficiency of wafer area having less defects even though the diameter is reduced as much as 10 mm by the grinding process of the wafer edge, furthermore, provides less defects density allover the processed wafer. The decrease in defect density by the present invention from that of the prior art method can be supposed to be owing to the suppression of the dust generated out of the wafer itself under process, because the jigs as well as the chemicals are quite identically used except the existance of the grinding step.

[0021] FIG. 6 is a graph showing relation of the position of a single grinding step in the wafer processes versus defects density after completion of the wafer processes, when the position of the grinding step is varied from its earliest step through the final step of the wafer processes while the other process conditions are kept quite identical with those of the previous preferred embodiment. In the graph, the abscissa indicates a position of the single grinding step represented with an ordinal number of the wafer processes. In these wafer processes there are at least ten layer-formation steps, such as two steps for LOCOS mask of SiO₂/SiN₄; for SiO₂ LOCOS; for gate insulation oxide (SiO₂); for polycrystalline silicon gate; two steps for inter layer isolation (SiO₂/psg); for Al-Si wiring; and passivation layer (PSG/SiN₄). Furthermore, in the case of employing a barrier layer, TiN or TiW layer is added. SiO₂ film is sometimes required for the ion implantation to the source drain regions. In FIG. 6, small circles representatively show position P₁ at the begining of the process steps; position P₂ for the LOCOS step for forming the elements islolation 2-1; position P₃ for the formation of the gate isolation 2-2; position P₄ for the formation of the polycrystalline silicon gate 2-3; position P₅ for the formation of the PSG layer 2-5; position P₆ for the formation of aluminum wiring 5; position P₇ for the formation of the passivation layer 4; and position P₈ for the end of the process steps. The above-described grinding step carried out just before the wiring step (graphed in FIG. 3 and FIG. 4) corresponds to the data before position P₆ of FIG. 6. It is apparent from FIG. 6 that a single step of grinding the wafer edge carried out within a range of 1/3 to 5/6 from the beginning of the entire 90 steps of wafer processes can reduce the defects density down to below approximately 1/2 of that of the prior art. At position P₂, the abnormal depositon is not considerable yet, and majority of the dust is generated in the later steps; therefore the grinding is not effective there. At position P₇, the dust has been generated already at the ealier steps; therefore the grinding is not effective there. The step position where, among the entire steps of wafer processes, such a wafer edge grinding step should be carried out is appropriately determined in consideration of operation efficiency and its effects in view of the total flow of the wafer processes. In the fabrication of semiconductor devices where the production is in small quantity but in many kinds, it has been a general method that the wafers processed to a step prior to the formation of the wiring are stocked, and many different kinds of semiconductor devices having each variation of the patterns are fabricated later from the stock. Accordingly, it is most preferable to carry out the wafer edge grinding step just prior to the wiring formation process. Moreover, as shown in FIG. 4 the increase in the ground width causes no problem at all in view of preventing the dust generation. Therefore, a six inch diameter semiconductor wafer formed with semiconductor elements etc. on which a wiring is to be formed, and ground down to four inches or 5 inches, allows the subsequent wiring steps to use already existing production lines for five inch or four inch wafer. Thus, such semiconductor devices in small quantity but in many kinds that do not require production facilities of large size wafers can be efficiently produced. Still moreover, it is also advantageous in an improvement of the production efficiency as well as the production flexibility that the processes prior to the wiring process can be done on a common, large semiconductor wafer. Needless to say, in fabricating a semiconductor device in massive quantity it is convenient to use a same production line from the beginning to the final step.

[0022] Though in the above-described embodiment am example where, through the wafer processes, only once of wafer edge grinding was referred to; however, it is apparent that this grinding step may be carried out plural times depending on the requirements. It is also needless to say that such a process carried out on each layer deposition step of various layers is effective from the view point of protecting dust generation only.

[0023] Furthermore, though in the description of the preferred embodiment the entire circle of the wafer edge was ground, a portion having less chance to directly contact the jigs, etc. may be omitted to be ground. Then, the grinding process can be simplified, resulting in an improvement of the production efficiency.

[0024] FIGs. 7 schematically illustrates main steps of a second preferred embodiment of the method of the present invention. In FIGs. 7, detailed parts of the multiple layer 2, such as silicon dioxide layer 2-1, the gate insulation layer 2-2, a polycrystalline silicon layer 2-3, drain and source regions 3 and the PSG layer 2-5, are simply drawn as a multiple layer 2. The aluminum wiring 5 is not shown in FIG. 7(c). Part members in common with FIG. 3 are denoted with same numerals. The difference of the second preferred embodiment from the above described preferred embodiment is that in order to remove the abnormal protrusion 2′ on a wafer edge 1′ an etching process is employed in stead of the grinding process using a grinder wheel. Subsequent processes for fabricating the element isolating regions, gate electrode structure, source and drain regions and PSG film as inter-layer isolation are identical with those of the previous preferred embodiment. This state is shown in FIG. 7(a). Next, after a protection layer (not shown in the figure) formed of photo resist is deposited in the same way as that of the previous preferred embodiment, each of the multiple layers 2 is sequentially etched away by the use of an etching solution of hydrofluoric acid family or an etching solution formed of a mixture of hydrofluoric acid and nitric acid, etc. until the not-covered peripheral portion 1′ of the underlying silicon substrate 1 is exposed. This state is shown in FIG. 7(b). At this time, if the above-described protection layer has been coated only upon a surface forming the semiconductor elements, unnecessary layers deposited upon the opposite surface of the wafer during the vapor deposition process, etc. can be concurrently etched away. Then, after the protection layer is removed a wiring pattern is formed, in the same way as the previous preferred embodiment. This state is shown in FIG. 7(c). Thus, the wafer process is completed. It was confirmed that the etching of an approximately 5 mm width from the wafer edge for the entire circle of the wafer provides the equal effect of preventing dust generation to the previously described 5 mm grinding from the wafer edge.

[0025] Employing a selective etching solution in the etching step, the etching can be terminated on the surface of the original substrate; thus the wafer diameter does not become smaller for each time like the case of grinding. Therefore, this is particularly advantageous in fabricating such semiconductor devices that are produced on a same production line from the beginning through the end.

[0026] Furthermore, the etching process does not employ the material which itself produces the dust, such as the abrasive material; therefore, all the wafer processes can be done in a highly clean condition, advantageously resulting in an easy process control, too. It is needless to say that a dry etching may be also employed in place of the wet etching process.

[0027] Though in the above embodiments only the fabrication of MOS integrated circuit is referred to, the principle of the present invention can be applied not only to the fabrication of the MOS integrated circuit but also to the fabrication of any other type of semiconductor devices.

[0028] Though in the above embodiments only one of the multiple layers 2 is referred to, it is apparent that the layers formation can be carried out as many times as required, such as for forming multi-layer wirings, etc..

[0029] As described above, according to the present invention, an abnormal protrusion of deposited layers which has been formed on a wafer edge during wafer processes to fabricate semiconductor devices, and is likely to peel off on touching jigs etc. during wafer handling, thus causing dust generation, is removed by grinding or etching before it peels off. Therefore, the dust generation is suppressed even if the wafer edge contacts jig etc., resulting in an improvement of production yield of the semiconductor devices. Consequently, production yield of semiconductor devices, such as very high density, very highly integrated ICs, is particularly improved, thus resulting in a beneficial effect of achieving higher density, higher degree of integration of the semiconductor devices of sub-micron element sizes.

[0030] The many features and advantages of the invention are apparent from the detailed specification and thus, it is intended by the appended claims to cover all such features and advantages of the system which fall within the true spirit and scope of the invention. Further, since numerous modifications and changes may readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

1. A method of fabricating semiconductor devices, comprising the steps of:
preparing a semiconductor wafer, on an area of said wafer a functional semiconductor element being to be fabricated;
forming on said area at least one layer which is to become a member constituting said semiconductor element; and
grinding or etching a peripheral portion of said wafer having said layer fabricated thereon, so as to expose an edge of said wafer.

2. A method of fabricating semiconductor devices as recited in claim 1, wherein said grinding or etching step is carried out so as to remove a protrusion on said peripheral portion of said wafer.

3. A method of fabricating semiconductor devices as recited in claim 1, wherein said grinding or etching step is carried out so that said edge of of said peripheral portion shows a curvature having a mirror finish surface.

4. A method of fabricating semiconductor device as recited in claim 1, wherein prior to said grinding or etching step a protection layer is formed so as to cover at least a surface of said wafer, on said surface said semiconductor element is to be fabricated.

5. A method of fabricating semiconductor devices as recited in claim 1 or 4, wherein said grinding or etching step is carried out prior to a step of fabricating a wiring of said semiconductor device.

6. A method of fabricating semiconductor devices as recited in claim 1 or 4, wherein said grinding or etching step is carried out at least one time at a step positioning in an approximate range of 1/3 to 5/6 from the beginning of entire wafer processes for fabricating the semiconductor device.

7. A method of fabricating semiconductor devices as recited in claim 1 or 4, wherein said grinding or etching step is carried out at each step of forming said layer which is to become a member to constitute said semiconductor element.

Drawing